CN103900834A - Rail vehicle body structure large-size component fatigue test method and device - Google Patents
Rail vehicle body structure large-size component fatigue test method and device Download PDFInfo
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- CN103900834A CN103900834A CN201210574755.3A CN201210574755A CN103900834A CN 103900834 A CN103900834 A CN 103900834A CN 201210574755 A CN201210574755 A CN 201210574755A CN 103900834 A CN103900834 A CN 103900834A
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Abstract
The invention relates to a rail vehicle body structure large-size component fatigue test method and device. A finite element model simulation technology is utilized to simulate test conditions of a vehicle body structure member to be tested under the fatigue state of the whole vehicle so that steps of test loading conditions of the vehicle body structure member to be tested are confirmed; and corresponding loads are applied to the vehicle body structure member to be tested according to the test loading conditions obtained in the last step, and fatigue strength is detected. The method combining simulation analysis and test is adopted, and welding seam fatigue strength of stainless steel vehicle body structure large-size components like a side wall is rapidly and accurately tested so that operation is simple and feasible. With application of the test technology, accurate detection data can be provided, large amounts of real and effective test data can be accumulated, and analysis and research of vehicle fatigue safety and reliability are facilitated so that powerful basis is provided for vehicle fatigue safety and reliability.
Description
Technical field
The present invention relates to a kind of fatigue strength test method and apparatus, particularly the large parts fatigue test method of a kind of body construction for rail vehicle and device, belong to rail vehicle experimental technique field.
Background technology
Along with the propelling of Urbanization in China, the demand of city rail vehicle is also continuing to increase.The key factor of city railway vehicle guarantee of run steady city rule vehicle development, and vehicle fatigue reliability is the strong guarantee of related city rail vehicle stable operation, therefore vehicle evaluation method for fatigue reliability more and more receives publicity as a gordian technique.
Torture test is that test specimen or simulation parts stand alternate load and measure the foundation of its fatigue behaviour under various environment, is the main method of research and checking structural fatigue performance.Part or primary structural component torture test can be investigated by general fatigue tester and crack detection equipment, and large-size components or full machine torture test technology are due to the restriction of technology and equipment, more difficult completing at present.
Full size structure torture test is tested loading by the test load spectrum of simplifying with coordinated multi-point load mode conventionally.Whole process of the test comprises endurancing and damage tolerance test.The former object is to find the position of fatigure failure may occur and determine each dangerous position fatigue lifetime in intended life inner structure, the latter's object is to measure speed and the structure residual strength of Crack Extension, meanwhile, in test must carry out continuous detection to test specimen.
In city rail vehicle experimental technique field, be tending towards ripe for car body and large parts test of static strength technology thereof, main method is according to different strength criterions, at car body static strength test rack, full-scale car body or car body big parts is loaded and is assessed.But, for car body Stromeyer test, do not carry out owing to being subject to the restriction of test condition and experimental technique.Therefore, the Stromeyer test technology that is directed to the large component unit of city rail vehicle just seems particularly important, and this type of test is for guaranteeing that vehicle operating stability plays an important role.
Summary of the invention
Fundamental purpose of the present invention is to address the above problem, the large parts fatigue test method of a kind of track vehicle body structure and device are provided, can quick and precisely test as the fatigue strength of the large parts weld seams such as side wall, operation simple and feasible, and can provide and detect accurately data for the tired safe reliability of vehicle is analyzed and researched.
For achieving the above object, technical scheme of the present invention is:
The large parts fatigue test method of a kind of track vehicle body structure, comprising:
Utilize finite element model emulation technology, simulate the operating condition of test of body construction part to be tested under car load fatigue state, and determine the step of the test loading condition of body construction part to be tested with this;
The test loading condition drawing according to upper step, treats instruction carriage body structure part and applies respective loads, and the step that fatigue strength is detected.
Further, in the step of test loading condition of determining body construction part to be tested, also specifically comprise the steps:
Determine vehicle fatigue load operating mode;
According to the fatigue load operating mode drawing, treat instruction carriage body structure part and carry out finite element modeling, calculating and analysis, record body construction part to be tested respectively to shift value and key point stress value, displacement and the stress of the body construction part to be tested of correspondence position in the displacement of body construction part to be tested and stress and car load result of calculation are consistent, and determine test loading condition with this.
Further, described vehicle fatigue load is divided into vertical fatigue load and horizontal fatigue load two parts, and determines by following formula respectively;
Load × (1 ± 0.15) × g under vertical fatigue load=vehicle normal operating conditions;
Laterally load × (± the 0.15) × g under fatigue load=vehicle normal operating conditions.
Further, determining according to fatigue load operating mode in the step of test loading condition, utilize the method for going forward one by one finite element model to be retrained and loaded analysis.
Further, in the step detecting at the fatigue strength for the treatment of instruction carriage body structure part, also specifically comprise the steps:
According to test loading condition, determine load load(ing) point and the data collection point of body construction part to be tested;
Charger and data collector are arranged in to load load(ing) point and data collection point place, treat instruction carriage body structure part imposed load, carry out each data acquisition to shift value and key point stress value simultaneously;
The weld seam of key position is carried out to permeation flaw detection detection.
Further, fatigue strength detects and comprises the vertical tension test of overcrowding load working condition lower side wall and the test of proper working load lower side wall fatigue load loaded.
Further, described data collector comprises displacement meter and is attached at the foil gauge at the tested position of car body, described charger comprises actuator, described permeation flaw detection detects and adopts radiographic inspection to detect and infiltration detection, and described displacement meter, foil gauge and actuator are connected with control device by signal wire.
Another technical scheme of the present invention is:
The large parts fatigue experimental device of a kind of track vehicle body structure, comprising:
Body construction part to be tested;
Analogue means, for simulation, calculating, Analysis deterrmination test loading condition;
Charger, for loading to body construction part to be tested according to test loading condition;
Pick-up unit, for detection of body construction part to be tested respectively to the carrying out flaw detection of stress value and the key position weld seam of shift value, key point.
Further, described charger is multiple actuator, and multiple actuator are connected with hydraulic actuation cylinder by passage, and described actuator is connected with control computer.
Further, described pick-up unit comprises displacement meter, is attached at the foil gauge at the tested position of car body, permeates checkout equipment, radiographic inspection checkout equipment, and described displacement meter is connected with control computer with foil gauge.
To sum up content, the large parts fatigue test method of track vehicle body structure of the present invention and device, take the large parts of stainless steel laser welding tractor body structure as research object, the method combining with test by simulation analysis, fast, accurately the weld fatigue intensity of the large parts of stainless steel car body structure such as side wall is tested, operation simple and feasible, it is the important component part of the tired safe reliability of prediction vehicle, the use of this measuring technology, not only can provide and detect accurately data, the a large amount of authentic and valid test figures of accumulation, be conducive to the tired safe reliability of vehicle to be analyzed and researched simultaneously, for the tired safe reliability of vehicle provides strong foundation.
Accompanying drawing explanation
Fig. 1 is test unit structural representation of the present invention;
Fig. 2 is the load(ing) point arrangenent diagram of the present invention while carrying out the vertical tension test under overcrowding load working condition;
Fig. 3 is the displacement meter location drawing of the present invention while carrying out the vertical tension test under overcrowding load working condition;
Fig. 4 is the load(ing) point arrangenent diagram of the present invention while carrying out the test of fatigue load loaded under proper working load.
As shown in Figures 1 to 4, side wall 1, left window pillar 2, right window pillar 3, window entablature 4, window sill 5, side wall cantrail 6, side wall lower-edge beam 7, door pillar 8, framed side wallboard 9, tie bracket 10, actuator 11.
Embodiment
Below in conjunction with accompanying drawing and embodiment, the present invention is described in further detail:
As shown in Figure 1, the large parts fatigue experimental device of track vehicle body structure of the present invention, carry out the test of weld fatigue intensity take stainless steel laser weldering Car Body Structure in Subway part as subjects, parts as large in side wall, the headwall etc. of subway, can be widely used in the Laser Welding (LBW) car body test in China's operation.
In the present embodiment, test as body construction part to be tested using side wall 1.Side wall 1 is welded by left window pillar 2, right window pillar 3, window entablature 4, window sill 5, side wall cantrail 6, side wall lower-edge beam 7, door pillar 8 and framed side wallboard 9, and side wall 1 is stainless steel material, and each weld seam welds by Laser Welding (LBW).
The torture test of large parts completes on fatigue test board, and test unit comprises side wall to be tested 1, simulation dress
Put, charger and pick-up unit, analogue means is for simulation, calculating, Analysis deterrmination test loading condition, charger is for loading to side wall to be tested 1 according to test loading condition, and pick-up unit is for detection of the carrying out flaw detection of each stress value and the key position weld seam to shift value, key point of side wall 1.Wherein, charger adopts actuator 11, pick-up unit comprises displacement meter, foil gauge, infiltration checkout equipment and radiographic inspection checkout equipment etc. closely connected with the detected part of side wall 1, analogue means includes the computer of HyperWorks finite element software in being, the testing result of pick-up unit transfers in computer, and computer calculates, analyzes and shows.
22 actuator 11 are set altogether on fatigue test board, the loading frequency of actuator 11 is 0.01-10Hz, maximum static lotus 1000kN, maximum dynamic loading ± the 500kN of actuator 11, the hydraulic actuation cylinder of testing table is provided with 22 passages altogether, and 22 passages connect respectively 22 actuator 11,22 passages both can have been coordinated to load simultaneously, also can be divided into polycomponent and not control, work alone, not interfere with each other.
Fatigue test method of the present invention, by finite element method (fem) analysis and experimental technique, the operating condition of test of simulation side wall 1 under car load fatigue state, detects the fatigue strength at the crucial weld seam position on it.Concrete method of testing comprises the steps:
One, utilize emulation technology to determine test loading condition:
1, the vehicle fatigue load of car load is divided into vertical fatigue load and horizontal fatigue load two parts.
Load × (1 ± 0.15) × g under vertical fatigue load=vehicle normal operating conditions;
Laterally load × (± the 0.15) × g under fatigue load=vehicle normal operating conditions;
By above formula, determine vehicle fatigue load operating mode.
2, determine test loading condition according to HyperWorks finite element software.
2-1, the fatigue load operating mode drawing according to above formula, carry out finite element modeling, calculating and analysis to the side wall 1 of Laser Welding (LBW), records each stress value to shift value and key point of side wall 1.
Simulation calculation adopts HyperWork software to carry out modeling analysis, model adopts quadrangular plate shell unit to divide, having carried out local unit for significant points carefully draws, laser welded seam is simulated with the larger shell unit of slenderness ratio, averaging unit length is got 20mm, wherein, to the contributive structure of integral rigidity and local strength, as left window pillar 2, right window pillar 3, window entablature 4, window sill 5, side wall cantrail 6, side wall lower-edge beam 7, door pillar 8 etc. are all paid attention to.
2-2, mention side wall 1 finite element model go forward side by side row constraint and load analyze, the method that utilization is gone forward one by one, displacement and the stress of correspondence position side wall unit in the displacement of side wall 1 and stress and car load result of calculation are consistent, and then the operating condition of test of simulation side wall 1 under car load fatigue state, and each experimental tests loading condition while determining weld fatigue strength test with this.
Underframe is the main carrying position of vehicle, 1 of side wall plays the effect of transmitting vertical force, in the time that design side wall 1 is tested loading condition, adopt progressive method, this progressive method is interpreted as considering in conjunction with existing test condition, side wall cantrail 6 is retrained, first adjust the loading Position of side wall lower-edge beam 7, find the suitable load(ing) point consistent with car load correspondence position side wall element deformation, secondly, guarantee side wall element deformation under two states and the consistance of stress by finely tuning the load value of each load(ing) point.
Two, the fatigue strength at crucial weld seam position is detected:
Draw by above-mentioned emulation technology after the test loading condition of side wall 1 each load(ing) point, by working condition, side wall 1 each point loaded, and by detection device records side wall 1 respectively to shift value and the stress value of each key point, specifically comprise the steps.
In conjunction with existing test condition, side wall cantrail 6 is retrained by tie bracket 10, adjust the loading Position of side wall lower-edge beam 7, find the suitable load(ing) point consistent with car load correspondence position side wall element deformation, in the present embodiment, A, B, tri-load(ing) points of C are set on side wall lower-edge beam 7, then guarantee side wall element deformation under two states and the consistance of stress by finely tuning the load value of each load(ing) point.
This test is divided into two parts, is respectively the vertical tension test of overcrowding load working condition lower side wall and the test of proper working load lower side wall fatigue load loaded.
1, as shown in Figure 2, the vertical tension test of side wall 1 under overcrowding load working condition.
In this step, the quantity of actuator 11 is 3, respectively at the A of side wall lower-edge beam 7, and B, tri-loading Positions of C load, and the D position of side wall cantrail 5 retrains by tie bracket 10, at A, B, imposed load within the scope of tri-load(ing) point 400mm of C.70mm outside the side of A point and C point range gate column 7, the B point distance about 196mm of left window pillar 2 place, makes side wall 1 remain on full and down operating mode.A, B, the load loading direction of tri-load(ing) points of C is vertically downward, the direction of arrow in Fig. 2 is loading direction, and the load of loading is respectively 23.3kN, and loading direction is vertical with side wall lower-edge beam 7, the loading frequency of actuator 11 is 5Hz, and it is 2,000,000 times that target loads number of times.
Test need to gather side wall 1 respectively to shift value and the stress value of key position, stress value carrys out (not shown) detection by being attached at the foil gauge of collection point, shift value detects by the displacement meter (not shown) that is arranged on collection point, shift value and stress value are real-time transmitted to reception converter, receive converter shift value and stress value are converted into electric signal transmission to computer, the data that computer docking is received are carried out real time record, calculating, analysis, to determine the deformation of car body.
Shift value collection point layout position as shown in Figure 3, be respectively 1,2,3,4 points, 1 and 2 is arranged on left and right door pillar 7,1 and 2 bases apart from side wall lower-edge beam 6 are 1200mm, 3 and 4 are arranged on the position of window sill 4, base apart from side wall lower-edge beam 6 is 900mm, locates each displacement meter that arranges at 1,2,3,4.
The position of layouting of stress value collection point is separately positioned on four Men Jiao and four window angles place, at He Chuan angle place, each angle, 3 to 4 foil gauges is set.Now, gather and check whether the high stress areas stress numerical such as Men Jiao, window angle meets lower than yield stress.
2, as shown in Figure 4, the fatigue load loaded test of side wall 1 under proper working load.
Loading position and the load value of the fatigue load loaded test under proper working load, carry out in two steps:
The first step, 3 actuator 11 are separately positioned on 3 positions of A, B, C of side wall lower-edge beam 7, imposed load within the scope of load(ing) point 400mm, the D position of side wall cantrail 6 retrains by tie bracket 10, the side 250mm of A point and B point range gate column 7, C point is arranged on the position corresponding with left window pillar 3.Wherein, the loading direction vertical side wall lower-edge beam 7 that A point and C are ordered, from lateral side wall lower-edge beam 7 imposed loads of side wall lower-edge beam 7 (direction) vertically upward, the load that A is ordered is 20 kN, the load that C is ordered is 35 kN, the loading direction vertical side wall lower-edge beam 7 that B is ordered, but from the outside imposed load in inner side of side wall lower-edge beam 7 (direction) vertically downward, the load that B is ordered is 20kN.The direction of arrow in Fig. 4 is loading direction.
Second step, A, the B of side wall lower-edge beam 7, C load(ing) point increase dynamic load, the amplitude of load proper working load ± 15% scope inter-sync changes.The loading frequency of actuator 11 is 5Hz, and cycle index is 2,000,000 times.
In the process loading, the distortion of displacement meter and foil gauge induction car body unit under test, shift value and stress value are real-time transmitted to reception converter, receive converter shift value and stress value are converted into electric signal transmission to computer, the data that computer docking is received are carried out real time record, calculating, analysis, to determine the deformation of car body.
3, the weld seam of key position is carried out to permeation flaw detection inspection.
Detection for the unwilling laser welded seam of the heart utilizes XXQ2505 radiographic inspection equipment, adopt radiographic inspection (RT) nondestructiving detecting means detection laser welded seam area, arrangement adopts single wall transillumination, screen before sensitizing mode: shield after Pb0.03mm: Pb0.1mm, and, time basic development conditions in the time of 4 ~ 7min, 15min realizes photographic fixing above, and test detects operation at 500,000 times, 1,000,000 times, 1,500,000 times, 2,000,000 times four-stages respectively.
Adopt permeation flaw detection method for the weld seams of high stress areas such as door angle and the detection in heat-affected zone, carry out EN571 and EN1289 standard, this infiltration checkout equipment is take spraying process as main, detection faces white light degree >=1000Lx, time of penetration is 15min, and leaves the time of developing of 12min.
Test all finishes.
Use this stainless steel laser welding car body big parts fatigue strength test technology, can fast, accurately test stainless steel laser weldering car body big parts weld fatigue intensity, it is the important component part of the tired safe reliability of prediction vehicle, the use of this measuring technology, not only can accumulate a large amount of authentic and valid data, can accelerate on-the-spot test speed, for the tired safe reliability of vehicle provides strong foundation simultaneously.Guarantee vehicle stabilization and safe operation.
As mentioned above, given scheme content, can derive similar technical scheme in conjunction with the accompanying drawings and embodiments.In every case be the content that does not depart from technical solution of the present invention, any simple modification, equivalent variations and the modification above embodiment done according to technical spirit of the present invention, all still belong in the scope of technical solution of the present invention.
Claims (10)
1. the large parts fatigue test method of track vehicle body structure, is characterized in that, comprising:
Utilize finite element model emulation technology, simulate the operating condition of test of body construction part to be tested under car load fatigue state, and determine the step of the test loading condition of body construction part to be tested with this;
The test loading condition drawing according to upper step, treats instruction carriage body structure part and applies respective loads, and the step that fatigue strength is detected.
2. the large parts fatigue test method of track vehicle body structure according to claim 1, is characterized in that: in the step of test loading condition of determining body construction part to be tested, also specifically comprise the steps:
Determine vehicle fatigue load operating mode;
According to the fatigue load operating mode drawing, treat instruction carriage body structure part and carry out finite element modeling, calculating and analysis, record body construction part to be tested respectively to shift value and key point stress value, displacement and the stress of the body construction part to be tested of correspondence position in the displacement of body construction part to be tested and stress and car load result of calculation are consistent, and determine test loading condition with this.
3. the large parts fatigue test method of track vehicle body structure according to claim 2, is characterized in that: described vehicle fatigue load is divided into vertical fatigue load and horizontal fatigue load two parts, and determines by following formula respectively;
Load × (1 ± 0.15) × g under vertical fatigue load=vehicle normal operating conditions;
Laterally load × (± the 0.15) × g under fatigue load=vehicle normal operating conditions.
4. the large parts fatigue test method of track vehicle body structure according to claim 2, is characterized in that: determining according to fatigue load operating mode in the step of test loading condition, utilize the method for going forward one by one finite element model to be retrained and loaded analysis.
5. the large parts fatigue test method of track vehicle body structure according to claim 1, is characterized in that: in the step detecting at the fatigue strength for the treatment of instruction carriage body structure part, also specifically comprise the steps:
According to test loading condition, determine load load(ing) point and the data collection point of body construction part to be tested;
Charger and data collector are arranged in to load load(ing) point and data collection point place, treat instruction carriage body structure part imposed load, carry out each data acquisition to shift value and key point stress value simultaneously;
The weld seam of key position is carried out to permeation flaw detection detection.
6. the large parts fatigue test method of track vehicle body structure according to claim 5, is characterized in that: fatigue strength detects and comprises the vertical tension test of overcrowding load working condition lower side wall and the test of proper working load lower side wall fatigue load loaded.
7. the large parts fatigue test method of track vehicle body structure according to claim 5, it is characterized in that: described data collector comprises displacement meter and is attached at the foil gauge at the tested position of car body, described charger comprises actuator, described permeation flaw detection detects and adopts radiographic inspection to detect and infiltration detection, and described displacement meter, foil gauge and actuator are connected with control device by signal wire.
8. the large parts fatigue experimental device of track vehicle body structure, is characterized in that, comprising:
Body construction part to be tested;
Analogue means, for simulation, calculating, Analysis deterrmination test loading condition;
Charger, for loading to body construction part to be tested according to test loading condition;
Pick-up unit, for detection of body construction part to be tested respectively to the carrying out flaw detection of stress value and the key position weld seam of shift value, key point.
9. the large parts fatigue experimental device of track vehicle body structure according to claim 8, is characterized in that: described charger is multiple actuator, multiple actuator are connected with hydraulic actuation cylinder by passage, and described actuator is connected with control computer.
10. the large parts fatigue experimental device of track vehicle body structure according to claim 8, it is characterized in that: described pick-up unit comprises displacement meter, is attached at the foil gauge at the tested position of car body, permeates checkout equipment, radiographic inspection checkout equipment, and described displacement meter is connected with control computer with foil gauge.
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| CN106680118A (en) * | 2017-01-13 | 2017-05-17 | 辽宁忠旺铝合金精深加工有限公司 | Fatigue testing method for rail transportation vehicle body welding structure |
| CN108051172A (en) * | 2017-12-27 | 2018-05-18 | 湖南响箭重工科技有限公司 | Swing arm type landing leg fatigue test device and test method |
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| CN104515786A (en) * | 2015-01-08 | 2015-04-15 | 北京科技大学 | Method for detecting and analyzing internal defect evolution of metal casting in fatigue process |
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| CN108051172A (en) * | 2017-12-27 | 2018-05-18 | 湖南响箭重工科技有限公司 | Swing arm type landing leg fatigue test device and test method |
| CN109308393A (en) * | 2018-09-30 | 2019-02-05 | 中车齐齐哈尔车辆有限公司 | A kind of appraisal procedure and system of car body fatigue life |
| CN109308393B (en) * | 2018-09-30 | 2021-04-23 | 中车齐齐哈尔车辆有限公司 | Method and system for evaluating fatigue life of vehicle body |
| CN109781557A (en) * | 2019-03-06 | 2019-05-21 | 中车青岛四方机车车辆股份有限公司 | The weld fatigue test method of train body weld assembly |
| CN109781557B (en) * | 2019-03-06 | 2021-08-13 | 中车青岛四方机车车辆股份有限公司 | Weld fatigue testing method for train body welding assembly |
| CN112417588A (en) * | 2020-11-04 | 2021-02-26 | 华人运通(江苏)技术有限公司 | Vehicle structure design method and system |
| CN112417588B (en) * | 2020-11-04 | 2023-09-22 | 华人运通(江苏)技术有限公司 | Vehicle structure design method and system |
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